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Old 06-17-2004 | 08:34 AM
  #40  
Swager
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From: Baldwinsville, NY
Default RE: 4 Star 40 building has commenced!

Hey Pale!

The Fuselage goes together quite well. I was actually surprised. Everything fit pretty well. Have rubber bands ready. You do have to wet the front part forward of the canopy to get it to conform (directions will tell this). So have a light spray bottle ready. I use a hair spray bottle. I put the fuel tank bottom where the kit called for it. Some people install it down lower for a larger tank.

Ensure you get the engine torque line correct. I can post a picture of my engine compartment if you want. I fuel proofed the engine compartment also with epoxy.

I did the reinforcement aft of F3 (I believe it is F3), which is just aft of the TE of the wing.

Do a trial fit of the wing into the fuselage. I did this and could see I needed to sand the LE alittle bit more to get the wing to fit snug into the fuselage.

Do not cover the remaining part of the wing until you glue in the wing dowel (There are 2 panel left open after you do the first part of the wing). This is open so you can get glue to the dowel. Follow directions for sanding a point on the wing dowel and marking it (I used red chaulk to mark the point) for correct drill position on the wings LE. It works! If you can get a set of extra hands to hold the wing while drilling the dowel position, all the better.

Make sure you put in the additional support for the wing mounting bolt block in the fuselage. After you drill these out you have to tap them. Once they are tapped, added some CA to the holes and let them dry, this will stregthen the holes. When you drill for the holes for the wing mounting bolts ENSURE your wing cannot move, because it is mounted to the fuselage for this procedure!! I understand some builders drill the wing first, mount it, and then drill the fuselage mounting blocks using the holes in the wing as a guide. Anyone do this instead?

The insturuction will tell you to go to a procedure in the other manual to measure the wingtips to the back of the fuselage before you do your drilling to ensure correct wing position. Mine fell pretty much right on. Insure you do this! Mine was about 1/8th of an inch off after the wing was mounted, so it shifted alittle bit. I guess that is not too bad.

Mold a piece of ply and put it where you will screw in the tailwheel mount. I used a Sullivan and the extra support will help.

Putting in wing mounted servos was not as bad as I thought it would be. I enjoyed doing it. I will post pictures.

Epoxy the Control rod into the holes for each frame. This is give them more strength. I mounted the servos per direction. They went in pretty smooth I positioned the Rudder and Elevator servos sit almost on the cockpit base (1/2 of the servos almost rest on the base).

I did not receive a nylon (fiberglass) band with my kit, it was missing. I went out and bought 2" nylon tape and sprayed it with sticky adhesive. Some kind of 3M 77 stuff. Then I layed it down with finishing epoxy. It worked quite well. Do yourself a favor and go out and get some wider fiberglass tape for the wing joint. I sanded the bottom of the wing kinda smooth (80 grit, 180 grit, then 320 grit) but the top of the wing not as much as it is covered by the fuselage anyways.

If I think of anything more I will type them down. If you have any questions, please feel free to ask.

Have fun!!